IC Unit Sorting Layout for High-UPH Stable Tray Offloading
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Solution Overview
Problem
Existing unit processing systems face challenges in maintaining high UPH rates while efficiently removing reject units without disrupting the process and preventing units from becoming dislodged during packaging, especially during rapid offloading which can lead to eccentric loading.
Innovation Solution
A unit sorting system comprising a net table with first and second zones, a unit lifter for depositing units in a checkerboard pattern, a control system for identifying and removing rejected units, and an offloading system with a channel and tray stopper to align and securely hold units for steady flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If units are rapidly offloaded to maintain high UPH rates, then productivity increases, but units may become dislodged during packaging due to eccentric loading
Solution Approach 1:
The net table is divided into multiple zones (first zone, second zone, third zone) that process units in sequence. Units are deposited in a checkerboard pattern across these zones, which segments the loading process and distributes units more evenly across the tray, preventing eccentric loading while maintaining high throughput rates
Solution Approach 2:
The system transitions from linear sequential loading to a two-dimensional checkerboard deposition pattern across multiple zones. This dimensional change allows units to be distributed more uniformly across the tray surface, preventing eccentric loading and improving stability during rapid offloading
2Reliability
If reject units are removed from the batch, then quality control improves, but the UPH rate may be disrupted
Solution Approach 1:
The control system identifies rejected units and marks them for removal before the units are deposited on the net table. This preliminary identification allows the unit picker to remove rejected units in advance, ensuring that only approved units proceed to packaging and maintaining continuous flow without disrupting UPH rates
Solution Approach 2:
The unit picker assembly selectively extracts rejected units from the batch before deposition onto the net table. By removing defective units in advance, the system ensures quality control without creating bottlenecks, as the removal happens in parallel with the deposition process
3Stability of the object's composition
If units are deposited in a checkerboard pattern, then loading uniformity improves, but the device complexity increases
Solution Approach 1:
The net table is segmented into multiple zones with specific deposition patterns. The unit lifter is configured to deposit units in a checkerboard pattern across these zones, which simplifies the control logic by using predetermined zone assignments rather than complex real-time calculations, achieving loading uniformity without excessive complexity
Data Source
AI summary
A unit sorting system comprising: a net table for receiving units and a unit lifter for depositing said units on the net table; the net table having a first and second zone; wherein the unit lifter is arranged to engage a batch of units and then deposit a first half of the batch to the first zone and deposit a first half of the batch to the second zone.